Material-saving pizza carton

ABSTRACT

A pizza carton and blank of a structure similar to that shown in Correll U.S. Pat. No. 6,547,125 and comprising one or more of the following features: (1) a side wall connector panel attached to a bottom edge of a corner panel and to the bottom panel and being free of attachment to any other panel; (2) a cover closure comprising a cover flap disposed within a flap-receiving slot; (3) left and right side walls disposed non-parallel to one another; (4) a carton having left and right side walls each with a diagonal corner panel and a connector panel attached to a bottom edge of the corner panel and with the left and right side walls disposed non-parallel to one another; (5) a carton having non-parallel left and right side walls and the lower edge of left and right cover side flaps disposed non-oblique to the top edge of the side walls; (6) a carton having non-parallel left and right side walls and gradual-diminishing-height cover side flaps; (7) adjacent blanks having non-parallel side walls having a top edge of a side wall of the first blank being disposed non-oblique to the top edge of the corresponding side wall of the second blank; and (8) adjacent blanks having non-parallel side walls and a lower edge of a cover side flap of the first blank being disposed non-oblique to a lower edge of a cover side flap or a top edge of a side wall of the second blank.

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This is a continuation-in-part application of my application Ser.No. 10/431,984, entitled “Material-saving Blank and Box,” filed May 8,2003.

FIELD OF THE INVENTION

[0002] This invention relates to packaging in general and in particularto boxes and box blanks for food products such as pizza and the like.

DESCRIPTION OF PRIOR ART

[0003] Each year thousands of pizza businesses sell millions of hotpizzas for delivery and carry-out. The success of these businessesdepends to an extent on the cost and functionality of the boxes used forpackaging the product. Ideally, these boxes should be cost-effective andeasy to use.

[0004] The instant invention pertains to a blank and box that containsseveral structural enhancements that are applicable to a prior inventionof mine disclosed in Correll U.S. Pat. No. 6,547,125 granted Apr. 15,2003, and entitled “Material-saving Food Carton.” As such, the structureof the instant invention is quite similar to that of Correll '125, withdeviations occurring in the particular areas of structural innovation.The preferred embodiment of the invention disclosed in this prior patenthappens to be a non-fastened, non-rectangular, some-slanting-wall boxhaving a full-length cover panel. Therefore, where applicable thedisclosure, discussion, and terminology contained within this U.S. Pat.No. 6,547,125 is included herein by this reference thereto. In addition,the instant invention also relates to a prior invention of minedisclosed in U.S. patent application Ser. No. 10/431,984 filed May 8,2003, and entitled “Material-saving Blank and Box.” As such, thestructure of the instant invention is quite similar to that of patentapplication Ser. No. 10/431,984, with deviations occurring in theparticular areas of structural innovation. Therefore, where applicablethe disclosure, discussion, and terminology contained within this U.S.patent application Ser. No. 10/431,984 is also included herein by thisreference thereto.

[0005] One of the ways of reducing the amount of material required formaking a box blank is to design the blank so that it can be oriented 180degrees to an adjacent similar blank and then mated (or nested) alongthe adjacent sides of the two blanks. This technique has been done fordecades within the packaging industry. One example is disclosed inLighter U.S. Pat. No. 2,435,283 granted Feb. 3, 1948. This patent showsa blank having a cover side flap that has a shorter height than the sidewall of the blank, thereby allowing one blank to be oriented 180 degreesto a similar adjacent blank and then mated together for manufacture.

[0006] The prior art also discloses Zion et al. U.S. Pat. No. 4,765,534granted Aug. 23, 1988; Deiger U.S. Pat. No. 4,919,326 granted Apr. 24,1990; Philips et al. U.S. Pat. No. 5,702,054 granted Dec. 30, 1997; andCorrell U.S. Pat. No. 6,206,277 granted Mar. 27, 2001. Each of thesepatents discloses a particular type of structure comprising a side wallattached to a bottom panel, a corner panel attached to an end of theside wall, a connector panel attached to a bottom edge of the cornerpanel, and an end wall panel attached to the bottom panel. In addition,Deiger, Philips et al., and Correll '277 each also disclose an end flapattached to an end of the end wall panel and also to the connectorpanel.

[0007] Philips et al., in particular, depicts the structure of the pizzabox and box blank currently in use by Domino's Pizza.

[0008] Each of the above-cited prior art has a particular drawback.Specifically, Lighter discloses how to mate adjacent blanks of aparticular structure but does not disclose how to mate adjacent blankshaving a structure similar to that of the Domino's Pizza pizza box blank(or Philips et al.) Zion et al., Deiger, Philips et al., and Correll'277 disclose how to create a non-slanting end wall on a box having astructure similar to the Domino's Pizza pizza box, but do not disclosehow to create a material-saving inward-slanting end wall. Further, theydo not disclose how to save material by mating adjacent blanks having astructure similar to that of the Domino's Pizza pizza box blank (orPhilips et al.).

[0009] In addition, Correll U.S. Pat. No. 5,381,949 granted Jan. 17,1995, and Correll U.S. Pat. No. 5,713,509 granted Feb. 3, 1998, alsodisclose adjacent nesting blanks. However, they do not disclose how tomate adjacent blanks having a structure similar to that of the Domino'sPizza pizza box blank (or Philips et al.) In addition to materialsavings derived from nesting of adjacent blanks, it would be desirableto have a pizza box that has a structure that affords a unique shape.One way this can be achieved is by having non-parallel side walls. Priorart structures of this type are disclosed in Lacasa et al. U.S. Pat. No.4,620,666 granted Nov. 4, 1986; Geho U.S. Pat. No. 5,118,032 grantedJun. 2, 1992; Correll U.S. Pat. No. 5,918,797 granted Jul. 6, 1999; andCorrell U.S. Pat. No. 5,961,035 granted Oct. 5, 1999. However, they donot disclose non-parallel side walls on a box and blank of the typedisclosed in my U.S. Pat. No. 6,547,125. Further, they do not disclosehow to nest adjacent blanks during manufacture to achieve optimalmaterial savings when a blank has non-parallel side walls. Finally, theydo not disclose a unique assembly of wall panel angles and lengths whichprovides a uniquely structured carton shape.

[0010] In conclusion, it would be highly desirable to provide a pizzabox and blank that overcomes the above-cited drawbacks and furtherenhances the box and blank disclosed in Correll U.S. Pat. No. 6,547,125,and, thereby, satisfies the need for further material savings, ease ofuse, and unique appearance. Nothing in the prior art does that. However,my invention does.

SUMMARY OF THE INVENTION

[0011] My invention is a carton and/or blank that can incorporate one ormore of the following features:

[0012] 1) A unique carton and blank structure similar to that shown inCorrell U.S. Pat. No. 6,547,125 and including a side wall with adiagonal corner panel attached to an end thereof and a connector panelattached to a bottom edge of the corner panel and to the bottom paneland being free of attachment to any other panel;

[0013] 2) A unique carton and blank structure similar to that shown inCorrell U.S. Pat. No. 6,547,125 and including a cover closure comprisinga cover flap disposed within a flap-receiving slot disposed in a frontwall structure;

[0014] 3) A unique carton having an end wall disposed at an acute angleto a bottom panel and left and right side walls disposed at a non-acuteangle to the bottom panel and disposed non-parallel to one another;

[0015] 4) A unique carton having left and right side walls each with adiagonal corner panel and a connector panel attached to a bottom edge ofthe corner panel and overlying a bottom panel and with the left andright side walls disposed non-parallel to one another;

[0016] 5) A unique box blank having left and right side walls disposednon-parallel to one another and the lower edge of left and right coverside flaps disposed non-oblique to the top edge of the left and rightside walls;

[0017] 6) A unique box blank having left and right side walls disposednon-parallel to one another and gradual-diminishing-height cover sideflaps;

[0018] 7) First and second blanks disposed side-by-side and each havingnon-parallel left and right side walls and gradual-diminishing-heightcover side flaps and a top edge of a side wall of the first blank beingdisposed non-oblique to the top edge of the corresponding side wall ofthe second blank;

[0019] 8) First and second blanks disposed side-by-side and each havingnon-parallel left and right side walls and gradual-diminishing-heightcover side flaps and a lower edge of the cover side flap of each blankbeing disposed non-oblique to at least one of the lower edge of thecover side flap and the top edge of the side wall of the other blank;and

[0020] 9) A unique box having non-parallel left and right rearward sidewalls disposed at a first obtuse angle to a rear end wall andnon-parallel left and right forward side walls disposed at a secondobtuse angle to the rearward side walls, with the first obtuse anglebeing less than the second obtuse angle.

[0021] My invention typically would be used for packaging relativelyflat food products such as pizza; however, it could take other forms forother purposes, as well.

[0022] A complete understanding of the invention can be obtained fromthe detailed description that follows.

OBJECT AND ADVANTAGES

[0023] The main object and advantages of my invention are as follows:

[0024] A main object of the instant invention is to enhance the box andblank disclosed in Correll U.S. Pat. No. 6,547,125 entitled“Material-saving Food Carton” and make it more adaptable to a variety ofcarton shapes, structural configurations, and material-savingopportunities.

[0025] A first advantage of my invention is manufacturing flexibility orthe opportunity to create a carton having an appearance andfunctionality similar to that of the box disclosed in Correll U.S. Pat.No. 6,547,125 but while using a slightly different side wall structureand/or cover closure structure.

[0026] A second advantage of my invention is an opportunity to create abox having non-parallel side walls and which can be manufactured with amaterial savings and has a unique shape.

[0027] Further objects and advantages of the invention will becomeapparent from consideration of the following detailed description,related drawings, and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0028]FIG. 1 is a plan view of multiple units of a preferred embodimentof the box blank.

[0029]FIG. 2 is a perspective view of a carton erected from the blank.

[0030]FIG. 3 is a plan view of a section of the blank.

[0031]FIG. 4 is a side sectional view of the carton taken along line 4-4of FIG. 2 (with the carton holding a pizza).

[0032]FIG. 5 is a front sectional view of the carton taken along line5-5 of FIG. 2.

[0033]FIG. 6 is a top view of the carton (with the cover removed).

LIST OF REFERENCE NUMERALS

[0034] Within a drawing, closely related components have the same numberbut different alphabetic suffixes. Between drawings, like referencenumerals designate corresponding parts.

[0035]10 blank of the preferred embodiment

[0036]10 a blank of the preferred embodiment

[0037]12 box of the preferred embodiment

[0038]20 bottom panel

[0039]22 rear end wall

[0040]24 rear wall fold line

[0041]30 side wall structure

[0042]32 side wall (a.k.a. rearward side wall)

[0043]34 side wall fold line

[0044]36 diagonal corner panel (a.k.a. forward side wall)

[0045]37 fold line

[0046]38 connector panel

[0047]39 fold line (bottom edge of corner panel)

[0048]40 front end of diagonal corner panel

[0049]42 acute angle

[0050]44 rear end of side wall

[0051]46 oblique angle (acute angle)

[0052]48 top edge of side wall

[0053]50 front wall structure

[0054]52 front end wall

[0055]54 front wall fold line

[0056]56 ancillary panel

[0057]58 flap-receiving means

[0058]59 outer edge

[0059]60 cover

[0060]62 cover panel

[0061]64 cover panel fold line

[0062]66 cover front flap

[0063]68 cover front flap fold line

[0064]69 bottom edge of cover front flap

[0065]70 cover side flap structure

[0066]72 cover side flap

[0067]74 cover side flap fold line

[0068]75 front end of cover side flap

[0069]76 corner flap

[0070]78 corner flap fold line

[0071]80 oblique angle (obtuse angle)

[0072]82 lower edge of corner flap

[0073]84 lower edge of cover side flap

[0074]90 front-to-rear length of bottom panel

[0075]92 front-to-rear length of cover panel

[0076]101 pizza

[0077]103 acute angle

[0078]105 acute angle

[0079]106 imaginary extension line of lower edge of cover side flap

[0080]108 imaginary extension line of top edge of side wall

[0081]110 first height location

[0082]112 second height location

[0083]114 oblique angle (obtuse angle)

[0084]116 oblique angle (obtuse angle)

[0085]118 oblique angle (obtuse angle)

[0086]119 oblique angle (obtuse angle)

[0087]120 length of rear end wall

[0088]122 length of rearward side wall (a.k.a. side wall)

[0089]124 length of forward side wall (a.k.a. diagonal corner panel)

[0090]126 length of front end wall

DESCRIPTION OF A PREFERRED EMBODIMENT

[0091] The instant invention constitutes, in large part, improvementsintended for use, among other things, in the box and blank disclosed inCorrell U.S. Pat. No. 6,547,125 granted Apr. 15, 2003, and entitled“Material-saving Food Carton.” As such, the structure of the instantinvention is somewhat similar to that of Correll '125, with deviationsoccurring in the particular areas of structural innovation. Therefore,where applicable, the disclosure, discussion, and terminology containedwithin this U.S. Pat. No. 6,547,125 is hereby included herein by thisreference thereto. In addition, the instant invention also relates to aprior invention of mine disclosed in U.S. patent application Ser. No.10/431,984 filed May 8, 2003, and entitled “Material-saving Blank andBox.” As such, the structure of the instant invention is somewhatsimilar to that of patent application Ser. No. 10/431,984, withdeviations occurring in the particular areas of structural innovation.Therefore, where applicable, the disclosure, discussion, and terminologycontained within this U.S. patent application Ser. No. 10/431,984 isincluded herein by this reference thereto.

[0092] The preferred embodiment is created from corrugated board;however, other foldable materials can be used, as well. The intended usefor the embodiment is for erecting into a pizza carton, or box. However,it will be appreciated, as the description proceeds, that my inventionmay be realized in different embodiments and used in differingapplications.

[0093]FIG. 1 shows a first blank 10 and a second blank 10 a oriented at180 degrees to blank 10. Even though only a partial section of blank 10a is depicted, this blank is of identical structure to that of blank 10.FIG. 2 shows a fully-erected pizza carton 12 created from blank 10.Referenced components are labeled in FIG. 1; selected components arelabeled in other Figures. Corresponding parts between drawings share asame reference numeral. It is noted that the invention is bilaterallysymmetrical (i.e., having identical left and right sides). Therefore,pairs of opposing like components are to be found, with one item of thepair on each side of the blank or carton. For simplicity of labeling,each component of the opposing pair will have the same referencenumeral. Also, a pair may be indicated by a numeral on one side of thedrawing only. Where this occurs, it is to be understood that thediscussion also applies to the corresponding component on the otherside, even though that component may not be numerically labeled.

Structure of the Embodiment

[0094] Referring in particular to FIG. 1 which shows blank 10, there isa bottom panel 20, a rear end wall 22 hingedly attached to bottom panel20 at a rear wall fold line 24, and opposing left and right side wallstructures 30.

[0095] Each side wall structure 30 comprises a side wall 32 hingedlyattached to bottom panel 20 at a side wall fold line 34 which isdisposed at an oblique angle 114 (specifically, an obtuse angle) to rearwall fold line 24, a front diagonal corner panel 36 hingedly attached toa front end of side wall 32 at a fold line, a connector panel 38hingedly attached to a bottom edge 39 of diagonal corner panel 36 at afold line (also depicted by numeral 39) and to bottom panel 20 at a foldline 37. Front diagonal corner panel 36 has a front end 40 that isobliquely disposed, or at an acute angle 42, to bottom edge 39 (in thepreferred embodiment angle 42 is approximately 62 degrees). Side wall 32has a rear end 44 that is obliquely disposed, or at an acute angle 46,to side wall fold line 34 (in the preferred embodiment angle 46 isapproximately 68 degrees). The optimal disposition of fold lines and thesizes of these angles depends on several factors, including the type ofcorrugated board used in making the blank and the degree ofinward-slanting angle desired on front and rear end walls 52/22 of thecarton. Therefore, the determination of the optimal disposition of foldlines and the degree of angle between fold lines will likely need to bederived from testing, a function easily accomplished by any box designerskilled in the art.

[0096] A couple differences between the box disclosed in Correll U.S.Pat. No. 6,547,125 and the carton of the instant invention are nownoted. First, in the box of U.S. Pat. No. 6,547,125, connector panel 38is not only attached to diagonal corner panel 36 and to bottom panel 20but is also attached to end flap 55 which is part of the front wallstructure. Whereas, in the instant invention connector panel 38 isattached only to diagonal corner panel 36 and to bottom panel 20 and isfree of attachment to any other panels. This configuration is similar tothat disclosed in Zion et al. U.S. Pat. No. 4,765,534.

[0097] Second, in the box of U.S. Pat. No. 6,547,125, left and rightside walls 32 are parallel to one another and also perpendicular to rearend wall 22. Whereas, in the instant invention side walls 32 (or sidewall fold lines 34) are non-parallel to one another and also are at anoblique, or obtuse, angle 114 to rear end wall 22.

[0098] A front wall structure 50 comprises a front end wall 52 that ishingedly attached to bottom panel 20 at a front wall fold line 54 and anancillary panel 56 that is hingedly attached to a top edge of front endwall 52 at a pair of fold lines. Front wall structure 50 furthercomprises a flap-receiving means 58. In the format of blank 10,flap-receiving means 58 is a slit in the board. In the format of carton12, flap-receiving means 58 is a slot capable of receiving a cover flap.Finally, ancillary panel 56 has an outer edge 59.

[0099] A cover 60 comprises a full-length cover panel 62 hingedlyattached to rear end wall 22 at a cover panel fold line 64, a coverfront flap 66 hingedly attached to a front edge of cover panel 62 at acover front flap fold line 68, and left and right cover side flapstructures 70. Cover front flap 66 has a bottom edge 69. A differencebetween the box disclosed in Correll U.S. Pat. No. 6,547,125 and thecarton of the instant invention is now noted. Specifically, in the boxof U.S. Pat. No. 6,547,125, cover closure is achieved by having coverfront flap 66 disposed between end flaps 55 that are attached to ends ofthe front end wall. Whereas, in the instant invention cover closure isachieved by having cover front flap 66 disposed within a slot in thefront wall structure provided by flap-receiving means 58. Thisconfiguration is similar to that disclosed in Zion et al. U.S. Pat. No.4,765,534 and in numerous other boxes.

[0100] Each cover side flap structure 70 comprises agradual-diminishing-height cover side flap 72 hingedly attached to aside edge of cover panel 62 at a cover side flap fold line 74 that'sdisposed at an oblique angle 116 (specifically, an obtuse angle) tocover panel fold line 64. The cover side flap has a front end 75 that isfree of attachment. The side flap structure further comprises afree-swinging corner flap 76 hingedly attached to a rear end of coverside flap 72 at a corner flap fold line 78. Corner flap fold line 78 isdisposed at an oblique angle 80 to cover side flap fold line 74(specifically, in the preferred embodiment angle 80 is an obtuse angleof approximately 112 degrees). As a general rule, this angle should begreater than 95 degrees and less than 115 degrees, although otherdegrees are possible. The exact angle of the slope is whatever is neededto retain cover side flap 72 in a proper (vertical) position after blank10 has been folded into carton 12. The determination of this angle mayrequire testing, a function easily accomplished by any box designerskilled in the art.

[0101] It is also noted that corner flap 76 has a lower edge 82 that isnon-aligned with a lower edge 84 of cover side flap 72. Thedetermination of the optimal angle of lower edge 82 to lower edge 84will require testing. It is further noted that lower edge 82 is disposedlower than lower edge 84. Further, it is noted that lower edge 84 isdisposed non-parallel to cover side flap fold line 74. This featureenables multiple adjacent blanks to be mated during manufacture formaterial savings.

[0102] It is also noted that bottom panel 20 has a front-to-rear length90 and cover panel 62 has a front-to-rear length 92.

[0103] In a five centimeter (two-inch) high pizza box in the format ofthe preferred embodiment, front-to-rear length 92 can be substantiallyshorter than front-to-rear length 90 by approximately thirty eightmillimeters (one-and-a-half inch).

[0104] Once blank 10 is set up into carton 12 a number of specialstructural arrangements occur. As illustrated in FIG. 4 which shows aside sectional view of carton 12 containing a recently-cooked roundpizza 101 (this is the view taken along line 4-4 of FIG. 2), front andrear end walls 52/22 slant inward at substantially acute angles 103/105to bottom panel 20. So the purpose in having bottom panel length 90slightly longer than cover panel length 92 is to create adequate spacefront-to-rear within the box cavity for accommodating a properly-sizedpizza. As also seen in FIG. 4, the bottom panel's front-to-rear length90 is slightly longer than the pizza's diameter (by at least sixmillimeters) and the cover panel's front-to-rear length 92 issubstantially shorter than the pizza's diameter (by at least eightmillimeters). This arrangement effects a material savings over asimilarly-constructed box having all non-slanting walls (i.e., the boxshown in Philips et al. U.S. Pat. No. 5,702,054).

[0105] As can be seen in FIG. 5, which shows a front sectional view ofcarton 12 taken along line 5-5 of FIG. 2, side walls 32 are disposed ata non-acute angle to bottom panel 20 (specifically, in the preferredembodiment the non-acute angle is a 90 degree angle).

[0106] As can be seen in FIG. 2, diagonal corner panels 36 extenddiagonally forward from side walls 32. Connector panels 38 overliebottom panel 20. And front end 40 of those panels abuts front end wall52. Cover side flaps 72 are disposed exterior to side walls 32 (hencethey're sometimes called exterior cover side flaps) and corner flaps 76are perpendicular to the cover side flaps and disposed between rear end44 and rear end wall 22. Lower edge 82 of corner flap 76 contacts bottompanel 20, thereby holding cover side flaps 72 in vertical or erecteddisposition. Cover front flap 66 is disposed in flap-receiving means 58(which takes the form of a slot in the preferred embodiment).

[0107] Referring to FIG. 3 which shows a section of blank 10, a coupleunique aspects will now be noted as regards lower edge 84 of cover sideflap 72 and top edge 48 of side wall 32. First, it is noted that loweredge 84 is disposed non-parallel to cover side flap fold line 74. Thisresults in the height of cover side flap 72 at the front end beingsubstantially less than the height at the rear end. (At any givenlocation, the height of the cover side flap is the distance betweencover side flap fold line 74 and lower edge 84.) This structure makescover side flap 72 a gradual-diminishing-height cover side flap. As theterm is used herein, a “gradual-diminishing-height cover side flap” is acover side flap that has a lower edge, or a substantial portion of loweredge, that is non-parallel to the cover side flap fold line, therebycausing the cover side flap to have a plurality of differing heightsextending over the length of the side flap, thereby resulting in theside flap having a gradually diminishing height extending from a firstlocation to a second location on the flap. To illustrate, referring toFIG. 3 it can be seen that the height of cover side flap 72 diminishesfrom a first height location 110 to a second height location 112, withthe dimensioning arrow at each location representing the height of thecover side flap at that particular location.

[0108] Second, it is noted that lower edge 84 is disposed non-oblique totop edge 48. As used herein, the term “disposed non-oblique” as appliedto two lines or planes means that those two lines or planes, or theimaginary extension of those lines or planes, are either aligned orparallel to one another (as opposed to obliquely or perpendicularlydisposed to one another). FIG. 3 depicts an imaginary extension line 106of lower edge 84 and an imaginary extension line 108 of top edge 48(each depicted by a dashed line). As can be seen, the two lines areparallel; therefore, lower edge 84 and top edge 48 are “disposednon-oblique” to one another.

[0109] Referring to FIG. 6 which shows a top view of carton 12 (with thecover and ancillary panel removed to simplify illustration), it is notedthat the wall panels of the carton constitute a plurality of wall panelshaving a unique configuration of lengths and angles. First, it is notedthat left and right side wall panels 32 constitute a pair of opposingnon-parallel rearward side walls that are disposed at an obtuse angle114 to rear end wall 22. Second, it is noted that left and rightdiagonal corner panels 36 constitute a pair of opposing non-parallelforward side walls that are disposed at an obtuse angle 118 to therearward side walls and at an obtuse angle 119 to front end wall 52.Further, it is noted that rear end wall 22 has a length 120, rearwardside walls 32 have a length 122, forward side walls 36 have a length124, and front end wall 52 has a length 126. Finally, it is noted thatobtuse angle 114 is less than obtuse angle 118 and rearward side walllength 122 is longer than forward side wall length 124. Thisconfiguration of wall panel angles and lengths provides a pizza cartonstructure and shape unique in the industry. Also, it is noted thatobtuse angle 119 is less than 135 degrees and less than angle 118, andfront end wall length 126 is slightly shorter than rear end wall length120.

Mating of Multiple Blanks During Manufacture

[0110]FIG. 1, which shows identical blanks 10 and 10 a oriented at 180degrees to one another, depicts the configuration of multiple units ofthe preferred embodiment in a mated configuration for efficientmanufacture. Even though only a partial section of blank 10 a isdepicted, this blank is of identical structure to that of blank 10.Further, in the drawing a small gap exists between the blanks. This gapis provided for clarity of illustration. In the actual manufacture ofthese blanks this gap would likely not exist and, instead, a substantialportion of the adjacent edges of the blanks would be contiguous, or incontact with one another. (However, in the preferred embodiment, a smallknock-out would exist between the adjacent blanks in the region ofcorner flaps 76.) Specifically, lower edge 84 of cover side flap 72 ofeach blank contacts, or is contiguous with, top edge 48 of side wall 32of the other blank. It is further noted that the furthermost extremitiesat each end of each blank (constituted by bottom edge 69 of cover frontflap 66 and outer edge 59 of ancillary panel 56) are aligned with thefurthermost extremities of the adjacent blank. Further, it is noted thatthe structural arrangement whereby lower edge 84 is non-parallel tocover flap fold line 74 (or whereby cover side flap 72 is agradual-diminishing-height cover side flap) enables a mating-typearrangement between the blanks which results in less material usage.Still further, it is noted that lower edge 84 of each blank is disposednon-oblique with lower edge 84 and top edge 48 of the other blank.Finally, it is noted that top edge 48 of each blank is disposednon-oblique with top edge 48 of the other blank.

Method for Erecting the Blank into the Carton

[0111] Any method used for erecting the blank of Philips et al. '054patent or Correll '125 patent into a box can be used for erecting thepreferred embodiment into a box.

[0112] Specifically, the following method can be used, which is highlyefficient.

[0113] First, position the blank so that it's horizontal and with theinside surface up and cover front flap 66 next to the abdomen.

[0114] Second, with your hands placed near the rear end of cover sideflaps 72, simultaneously fold cover side flaps 72 inward and, with yourindex fingers, fold rear corner flaps 76 inward.

[0115] Third, while keeping your hands in that position (i.e., at therear end of cover side flaps 72) and while holding the cover side flapsupright, with your fingers pull rear end wall 22 upright.

[0116] Fourth, fold bottom panel 20 downward to about halfway closed.

[0117] Fifth, fold side walls 32 inward and position them interior tocover side flaps 72 and then fold bottom panel 20 down until the box isall the way, or almost all the way, closed.

[0118] Sixth, turn the partially-erected box to a vertical position withfront wall structure 50 up.

[0119] Seventh, open cover panel 62 about three inches and then, withyour index fingers, push both front diagonal corner panels 36 inward.Then fold front wall structure 50 to an upright position and withancillary panel 56 extending inward (perpendicular to front end wall52).

[0120] Eighth, fold cover front flap 66 down and tuck it into the slotproduced by flap-receiving means 58 and close the box completely. Thisstep can sometimes be most easily executed with the rear end of the boxheld against a surface. This can be accomplished by either (a) holdingthe box vertically with the rear end resting on a table or (b) holdingthe box horizontally with the rear end held against your abdomen.

Definition of Key Terms

[0121] Certain terms are used in the claims for describing theinvention. To insure clarity of meaning those terms are now specificallydefined as used herein.

[0122] A “front-to-rear length of a cover panel” is the distance betweenthe cover panel fold line (connecting the cover panel to the rear wall)and the cover front flap fold line (connecting the cover front flap tothe cover panel). The line of measurement is perpendicular to the coverpanel fold line and is measured at the furthest distance between the twofold lines.

[0123] A “front-to-rear length of a bottom panel” is the distancebetween the rear wall fold line (connecting the rear end wall to thebottom panel) and the front wall fold line (connecting the front endwall to the bottom panel). The line of measurement is perpendicular tothe rear wall fold line and is measured at the furthest distance betweenthe two fold lines.

[0124] A “substantially acute angle” is considered herein to be an angleof 85 degrees or less.

[0125] A “substantially non-acute angle” is considered herein to be anangle greater than 85 degrees.

[0126] A “full-length cover panel” is a cover panel that's hingedlyattached to a wall of the box and extends from that wall substantiallyall the way to an opposing wall structure.

[0127] An “inward-slanting wall” is a wall disposed at an acute angle toa bottom panel.

[0128] A “perimeter edge of a cover panel” is one of the front, rear,left, or right side edges of a cover panel.

[0129] A “free-swinging” flap or panel is one that is attached to onlyone other flap or panel after the blank has been erected into a box. Anexample is corner flap 76.

[0130] A “height of a cover side flap” is the distance between the coverside flap fold line and the lower edge of the cover side flap. A coverside flap that has a lower edge disposed non-parallel to the cover sideflap fold line has a plurality of differing heights extending over thelength of the side flap.

[0131] A “gradual-diminishing-height cover side flap” is a cover sideflap that has a lower edge, or a substantial portion of lower edge, thatis non-parallel to the cover side flap fold line, thereby causing thecover side flap to have a plurality of differing heights extending overthe length of the side flap, thereby resulting in the side flap having agradually diminishing height extending from a first height location to asecond height location. It is noted that an inward-angling, or beveled,end edge of a cover side flap is not considered to be a lower edge ofthe cover side flap and, therefore, does not render a cover side flap tobe a gradual-diminishing-height cover side flap.

[0132] When the term “disposed non-oblique” is used to describe therelationship of two lines or planes it means that those two lines orplanes, or the imaginary extension of those lines or planes, are eitheraligned or parallel to one another (as opposed to obliquely orperpendicularly disposed to one another).

[0133] The term “rearward side wall” refers to a side wall disposedadjacent to a rear end wall. The term “forward side wall” refers to aside wall disposed adjacent to and forward of a rearward side wall. Incarton 12, side wall 32 constitutes a particular type of rearward sidewall and diagonal corner panel 36 constitutes a particular type offorward side wall.

[0134] The terms “carton” and “box” are synonymous and usedinterchangeably herein.

[0135] Within the drawing of blank 10, a fold line between componentparts of the invention is depicted with a dashed line. Within thecontext of this invention, a fold line can be created by a number ofmeans such as, for example, by a crease or score in the board, by aseries of aligned spaced short slits in the board, by a combination ofaligned spaced short and long slits, or by a combination of a slit and ascore.

[0136] In some cases, when a longer slit is bounded on the ends by aseries of shorter slits or a score, the longer slit may be slightlyoffset in alignment from the shorter slits or score for the purpose ofcreating a slot along the fold line when the blank is set up into a box.Such an offset slit may be referred to herein as a “slot-forming slit.”Nonetheless, the entire combination of long and short slits isconsidered to constitute a single fold line unless otherwise indicated.

[0137] In addition, to create a fold line where one panel is folded 180degrees to lay parallel on another panel, the fold line may constitutetwo narrowly-spaced parallel scores or series of aligned slits. In thiscase, the two narrowly-spaced parallel scores or series of aligned slitsconstitute a single fold line unless otherwise indicated.

[0138] In conclusion, as referred to herein, a fold line is any linebetween two points on the blank or box along which the board is intendedto be folded when the blank is being erected into a box or when the boxis being manipulated as described herein. The type of fold lines shownin the drawings are presently preferred but it will be appreciated thatother methods known to those skilled in the art may be used.

Conclusion, Ramifications, and Scope

[0139] I have disclosed a pizza carton and blank embodying one or moreof the following structural features:

[0140] 1) A unique carton and blank structure similar to that shown inCorrell U.S. Pat. No. 6,547,125 and including a side wall with adiagonal corner panel attached to an end thereof and a connector panelattached to a bottom edge of the corner panel and to the bottom paneland being free of attachment to any other panel;

[0141] 2) A unique carton and blank structure similar to that shown inCorrell U.S. Pat. No. 6,547,125 and including a cover closure comprisinga cover flap disposed within a flap-receiving slot disposed in a frontwall structure;

[0142] 3) A unique carton having an end wall disposed at an acute angleto a bottom panel and left and right side walls disposed at a non-acuteangle to the bottom panel and disposed non-parallel to one another;

[0143] 4) A unique carton having left and right side walls each with adiagonal corner panel and a connector panel attached to a bottom edge ofthe corner panel and overlying a bottom panel and with the left andright side walls disposed non-parallel to one another;

[0144] 5) A unique box blank having left and right side walls disposednon-parallel to one another and the lower edge of left and right coverside flaps disposed non-oblique to the top edge of the left and rightside walls;

[0145] 6) A unique box blank having left and right side walls disposednon-parallel to one another and gradual-diminishing-height cover sideflaps;

[0146] 7) First and second blanks disposed side-by-side and each havingnon-parallel left and right side walls and gradual-diminishing-heightcover side flaps and a top edge of a side wall of the first blank beingdisposed non-oblique to the top edge of the corresponding side wall ofthe second blank;

[0147] 8) First and second blanks disposed side-by-side and each havingnon-parallel left and right side walls and gradual-diminishing-heightcover side flaps and a lower edge of the cover side flap of each blankbeing disposed non-oblique to at least one of the lower edge of thecover side flap and the top edge of the side wall of the other blank;and

[0148] 9) A unique box having non-parallel left and right rearward sidewalls disposed at a first obtuse angle to a rear end wall andnon-parallel left and right forward side walls disposed at a secondobtuse angle to the rearward side walls, with the first obtuse anglebeing less than the second obtuse angle.

[0149] Within the foregoing discussion of the invention, the labeling ofany components by a numerical adjective (i.e., “first,” “second,” etc.)is for reference purposes only and does not denote any particularlocation of the components within the blank or carton. Further, the term“hingedly attached” refers to two panels (or a panel and a flap) joinedtogether at a fold line, and does not imply any degree of movability ofthe panels in the erected box format.

[0150] The illustrated number, size, shape, type, and placement ofcomponents represent the preferred embodiment; however, many othercombinations and configurations are possible within the scope of theinvention. Examples of some alternate configurations are describedbelow.

[0151] The foregoing discussion has pertained mainly to packagingrelatively flat food products such as pizza. However, it should berealized that my invention could be used for other purposes, as well. Inconclusion, it is understood that the invention is not to be limited tothe disclosed embodiments but, on the contrary, is intended to covervarious modifications and equivalent arrangements included within thespirit and scope of the appended claims, which scope is to be accordedthe broadest interpretation so as to encompass all such modificationsand equivalent structures as is permitted under the law.

1. A non-fastened pizza carton having material-saving dimensions and adiagonal corner panel structure free of attachment to an end wall, saidcarton being of foldable material and comprising: a bottom panel havinga predetermined front-to-rear length, opposing front and rear end walls,a side wall structure comprising a side wall, a diagonal corner panelattached to an end of said side wall and extending at least part way toone of said front and rear end walls, and a connector panel, and afull-length cover panel hingedly attached to said rear end wall andextending substantially all the way to said front end wall and having apredetermined front-to-rear length; wherein: (a) the predeterminedfront-to-rear length of said full-length cover panel is substantiallyshorter than the predetermined front-to-rear length of said bottompanel, (b) at least one of the front and rear end walls is disposed at asubstantially acute angle to said bottom panel and said side wall isdisposed at a substantially non-acute angle to said bottom panel, and(c) said connector panel overlies said bottom panel and is attached to abottom edge of said diagonal corner panel and to said bottom panel andis free of attachment to any other panel.
 2. The non-fastened pizzacarton of claim 1 wherein: said cover further comprises a cover sideflap structure comprising a cover side flap attached to said cover panelat a cover side flap fold line and a corner flap attached to a rear endof said cover side flap at a corner flap fold line and disposed betweenan end of said side wall and said rear end wall, said corner flap foldline being disposed at an oblique angle to said cover side flap foldline.
 3. A non-fastened pizza carton having material-saving dimensions,a diagonal corner panel structure, and a flap-in-slot cover closure,said carton comprising: a bottom panel having a predeterminedfront-to-rear length, a rear end wall, a front wall structure opposingsaid rear end wall and comprising a front wall, a side wall structurecomprising a side wall, a diagonal corner panel attached to an end ofsaid side wall and extending at least part way to one of said front andrear end walls, and a connector panel attached to a bottom edge of saiddiagonal corner panel and overlying said bottom panel, and a full-lengthcover panel hingedly attached to said rear end wall and extendingsubstantially all the way to said front end wall and having apredetermined front-to-rear length; wherein: (a) the predeterminedfront-to-rear length of said full-length cover panel is substantiallyshorter than the predetermined front-to-rear length of said bottompanel, (b) at least one of the front and rear end walls is disposed at asubstantially acute angle to said bottom panel and said side wall isdisposed at a substantially non-acute angle to said bottom panel, and(c) said cover further comprises a cover flap and said front wallstructure further comprises a flap-receiving means and said cover flapis disposed within said flap-receiving means.
 4. The non-fastened pizzacarton of claim 3 wherein: said cover further comprises a cover sideflap structure comprising a cover side flap attached to said cover panelat a cover side flap fold line and a corner flap attached to a rear endof said cover side flap at a corner flap fold line and disposed betweenan end of said side wall and said rear end wall, said corner flap foldline being disposed at an oblique angle to said cover side flap foldline.
 5. A non-fastened carton having an inward-slanting end wall andnon-parallel side walls, said carton comprising: a bottom panel,opposing front and rear end walls, and opposing left and right side wallstructures comprising respective left and right side walls disposednon-parallel to one another and adjacent said rear end wall; wherein:(a) at least one of said front and rear end walls is disposed at asubstantially acute angle to said bottom panel and said left and rightside walls are each disposed at a substantially non-acute angle to saidbottom panel, and (b) said left and right side walls are each disposedat an obtuse angle to said rear end wall.
 6. The non-fastened carton ofclaim 5 further comprising: a cover comprising a cover panel attached tosaid rear end wall and a cover side flap structure comprising a coverside flap attached to said cover panel at a cover side flap fold lineand a corner flap attached to a rear end of said cover side flap at acorner flap fold line and disposed between an end of said side wall andsaid rear end wall, said corner flap fold line being disposed at anoblique angle to said cover side flap fold line
 7. A non-fastened cartonhaving diagonal corner panels and non-parallel side walls, said cartoncomprising: a bottom panel, opposing front and rear end walls, andopposing left and right side wall structures comprising respective leftand right side walls hingedly attached to said bottom panel, left andright diagonal corner panels attached to respective ends of said leftand right side walls and extending at least part way to one of saidfront and rear end walls, and left and right connector panels attachedto respective bottom edges of said left and right diagonal corner panelsand overlying said bottom panel; wherein said left and right side wallsare non-parallel to one another.
 8. The non-fastened carton of claim 7wherein: at least one of said front and rear end walls is disposed at asubstantially acute angle to said bottom panel and said left and rightside walls are each disposed at a substantially non-acute angle to saidbottom panel.
 9. The non-fastened carton of claim 7 further comprising:a cover comprising a cover panel attached to said rear end wall and acover side flap structure comprising a cover side flap attached to saidcover panel at a cover side flap fold line and a corner flap attached toa rear end of said cover side flap at a corner flap fold line anddisposed between an end of said side wall and said rear end wall, saidcorner flap fold line being disposed at an oblique angle to said coverside flap fold line.
 10. A blank for a carton having non-parallel sidewalls, said blank being of foldable material cut and scored to define: abottom panel, a rear end wall hingedly attached to said bottom panel ata rear wall fold line, a front wall structure opposing said rear endwall and comprising a front end wall hingedly attached to said bottompanel, opposing left and right side wall structures comprisingrespective left and right side walls hingedly attached to said bottompanel at respective left and right side wall fold lines disposedadjacent said rear wall fold line and each having a top edge, and acover comprising a cover panel hingedly attached to said rear end wallat a cover panel fold line and opposing left and right cover side flapstructures comprising respective left and right cover side flapsattached to said cover panel at respective left and right cover sideflap fold lines disposed adjacent said cover panel fold line and eachhaving a lower edge; wherein: (a) said left and right side wall foldlines are non-parallel to one another, and (b) a substantial portion ofthe lower edge of said left and right cover side flaps is disposednon-oblique to a substantial portion of the top edge of said left andright side walls, respectively.
 11. The blank of claim 10 wherein: eachof said left and right cover side flaps is a gradual-diminishing-heightcover side flap.
 12. A blank for a carton having non-parallel sidewalls, said blank being of foldable material cut and scored to define: abottom panel, a rear end wall hingedly attached to said bottom panel ata rear wall fold line, a front wall structure opposing said rear endwall and comprising a front end wall hingedly attached to said bottompanel, opposing left and right side wall structures comprisingrespective left and right side walls hingedly attached to said bottompanel at respective left and right side wall fold lines disposedadjacent said rear wall fold line, and a cover comprising a cover panelhingedly attached to said rear end wall at a cover panel fold line andopposing left and right cover side flap structures comprising respectiveleft and right cover side flaps attached to said cover panel atrespective left and right cover side flap fold lines disposed adjacentsaid cover panel fold line and each having a lower edge; wherein: (a)said left and right side wall fold lines are non-parallel to oneanother, and (b) each of said left and right cover side flaps is agradual-diminishing-height cover side flap.
 13. First and second blanksformed from a single sheet of foldable material and disposedside-by-side, each of the blanks being cut and scored to define: abottom panel, a rear end wall hingedly attached to said bottom panel ata rear wall fold line, a front wall structure opposing said rear endwall and comprising a front end wall hingedly attached to said bottompanel, opposing left and right side wall structures comprisingrespective left and right side walls hingedly attached to said bottompanel at respective left and right side wall fold lines disposedadjacent said rear wall fold line, and a cover comprising a cover panelhingedly attached to said rear end wall at a cover panel fold line andopposing left and right cover side flap structures comprising respectiveleft and right cover side flaps attached to said cover panel atrespective left and right cover side flap fold lines disposed adjacentsaid cover panel fold line and each having a lower edge; wherein: (a)said left and right side wall fold lines are non-parallel to oneanother, (b) each of said left and right cover side flaps is agradual-diminishing-height cover side flap, and (c) a substantialportion of the top edge of at least one of the side walls of the firstblank is disposed non-oblique to a substantial portion of the top edgeof a corresponding side wall of the second blank.
 14. The first andsecond blanks of claim 13 wherein: said first and second blanks areoriented at one hundred eighty degrees from each other and the top edgeof one of the side walls of the first blank is disposed adjacent thelower edge of one of the cover side flaps of the second blank.
 15. Firstand second blanks formed from a single sheet of foldable material anddisposed side-by-side, each of the blanks being cut and scored todefine: a bottom panel, a rear end wall hingedly attached to said bottompanel at a rear wall fold line, a front wall structure opposing saidrear end wall and comprising a front end wall hingedly attached to saidbottom panel, opposing left and right side wall structures comprisingrespective left and right side walls hingedly attached to said bottompanel at respective left and right side wall fold lines disposedadjacent said rear wall fold line and each having a top edge, and acover comprising a cover panel hingedly attached to said rear end wallat a cover panel fold line and opposing left and right cover side flapstructures comprising respective left and right cover side flapsattached to said cover panel at respective left and right cover sideflap fold lines disposed adjacent said cover panel fold line and eachhaving a lower edge; wherein: (a) said left and right side wall foldlines are non-parallel to one another, (b) each of said left and rightcover side flaps is a gradual-diminishing-height cover side flap, and(c) a substantial portion of the lower edge of at least one of the coverside flaps of the first blank is disposed non-oblique to a substantialportion of at least one of the lower edge of a cover side flap and thetop edge of a side wall of the second blank.
 16. The first and secondblanks of claim 15 wherein: said first and second blanks are oriented atone hundred eighty degrees from each other and the top edge of one ofthe side walls of the first blank is disposed adjacent the lower edge ofone of the cover side flaps of the second blank.
 17. The first andsecond blanks of claim 15 wherein: a substantial portion of said loweredge of at least one of the cover side flaps of the first blank iscontiguous with a substantial portion of said top edge of a side wall ofthe second blank.
 18. A carton having a unique configuration of wallpanels, said carton comprising: (a) a bottom panel, (b) a plurality ofwall panels each having a predetermined length, said plurality of wallpanels comprising: (i) a rear end wall, (ii) opposing non-parallel leftand right rearward side walls each disposed at a predetermined obtuseangle to said rear end wall, (iii) opposing non-parallel left and rightforward side walls each disposed at a predetermined obtuse angle to saidfirst and second rearward side walls, respectively, and (c) a coverhingedly attached to said rear end wall; wherein: the predeterminedobtuse angle between said rear end wall and said left and right rearwardside walls is less than the predetermined obtuse angle between said leftand right rearward side walls and said left and right forward sidewalls, and the predetermined length of said left and right rearward sidewalls is longer than the predetermined length of said left and rightforward side walls.
 19. The carton of claim 18 wherein: said left andright forward side walls are hingedly attached to an end of said leftand right rearward side walls, respectively.
 20. The carton of claim 18wherein: said plurality of wall panels further comprises a front endwall opposing said rear end wall.
 21. The carton of claim 18 wherein:said plurality of wall panels further comprises a front end wallopposing said rear end wall, and at least one of the front and rear endwalls is disposed at an acute angle to said bottom panel.
 22. A blankfor a carton having uniquely-configured cover side flaps, said blankbeing of foldable material cut and scored to define: a bottom panel,opposing front and rear end walls hingedly attached to said bottom panelat respective front and rear wall fold lines, a side wall hingedlyattached to said bottom panel at a side wall fold line disposed adjacentsaid rear wall fold line and having a top edge, and a cover comprising(a) a cover panel hingedly attached to said rear wall at a cover panelfold line and (b) a cover side flap structure comprising (i) a coverside flap hingedly attached to said cover panel at a cover side flapfold line disposed adjacent said cover panel fold line and (ii) afree-swinging corner flap hingedly attached to a rear end of said coverside flap at a corner flap fold line, each of said cover side flap andsaid corner flap having a lower edge; wherein: (a) said corner flap foldline is disposed at an oblique angle to said cover side flap fold line,(b) a substantial portion of the lower edge of said corner flap isdisposed in non-alignment to a substantial portion of the lower edge ofsaid cover side flap, and (c) an imaginary extension line extending fromat least a substantial portion of the lower edge of said cover side flapis disposed parallel to an imaginary extension line extending from atleast a substantial portion of the top edge of said side wall.